CN115592517A - Intelligent flexible polishing method and device - Google Patents

Abstract

The invention provides an intelligent flexible polishing method and device, comprising the following steps: s110, scanning the outline of the polished part once to obtain point cloud data, and analyzing the difference value between the polished part and a preset model according to a preset algorithm by using the point cloud data; s120, dividing the point cloud data into a plurality of areas, analyzing the point cloud data of each area, calculating the spatial offset of each area and the area on the preset model, combining the spatial offset with the polishing area and the polishing process, and determining the polishing track of each area; s130, polishing the polishing piece for the first time by a polishing machine according to the polishing track of each area; and S140, after finishing polishing of each area, uploading a polishing result to the control system by the polishing machine, and issuing a polishing instruction of the next area after the control system confirms the polishing result until polishing of polishing tracks of all the areas is finished. By utilizing the intelligent flexible polishing method and the matched device thereof, the problems of low manual polishing efficiency and poor polishing consistency in the prior art can be effectively solved.

Description

Intelligent flexible polishing method and device

Technical Field

The invention relates to the field of intelligent polishing, in particular to an intelligent flexible polishing method and device.

Background

In the prior art, there are two methods of sanding a sanding element. 1. The cutter is held by an operator to polish, and in the process of polishing by mechanical machining, the cutter is used for a long time to lead to the passivation of a knife edge and influence subsequent processing. 2. The polishing piece is polished by a robot matching polisher, different polishing products need to be supported by support frames of different shapes, and the polishing piece is manually installed in the polishing process supported by the support frames, so that potential hazards are caused to the personal safety of operators when the operation is inconvenient.

Disclosure of Invention

In view of the above problems, the present invention provides an intelligent flexible polishing method and apparatus, which can effectively solve the problems of low manual polishing efficiency and poor polishing uniformity in the prior art.

According to one aspect of the invention, an intelligent flexible polishing method is provided, which comprises the following steps:

s110, scanning the outline of the grinding piece once to obtain point cloud data, analyzing the difference value between the grinding piece and a preset model according to a preset algorithm by using the point cloud data, and if the difference value exceeds a preset range, sending an alarm by a control system;

s120, dividing the point cloud data into a plurality of areas, analyzing the point cloud data of each area, calculating the spatial offset of each area and the area on the preset model, combining the spatial offset with the polishing area and the polishing process, and determining the polishing track of each area;

s130, polishing the polishing piece for the first time by a polishing machine according to the polishing track of each area;

and S140, after finishing polishing of each area, uploading a polishing result to the control system by the polishing machine, and issuing a polishing instruction of the next area after the control system confirms the polishing result until polishing of polishing tracks of all the areas is finished.

In addition, the preferred scheme is that the ground part after the primary grinding is finished is scanned secondarily, the control system analyzes point cloud data of the secondary scanning to determine the spatial offset of the ground part, when the spatial offset is larger than a preset offset, the control system sends a grinding instruction and coordinates of the position to be ground to the grinding machine, and the grinding machine grinds the position to be ground in a segmented mode.

In addition, in S110, preferably, the point cloud data is converted into a three-dimensional model, the three-dimensional model is compared with a preset model in a control system to confirm a polished bulge phenomenon, and when the bulge phenomenon occurs, the control system marks a bulge area and gives an alarm.

In addition, the preferable scheme is that a compensation value of the space offset is regulated and controlled, and the grinding times of the grinding piece are determined according to the compensation value and the feed amount of the grinding machine.

According to another aspect of the present invention, there is provided an intelligent flexible grinding device for performing the intelligent flexible grinding method, comprising:

the grinding machine is used for controlling the grinding track and the grinding operation of the cutter;

the scanning module is used for acquiring point cloud data of the surface of the polished workpiece, determining the spatial offset of the polished workpiece according to the point cloud data, and determining the polishing track of the cutter and the type of the cutter according to the spatial offset;

and the control system is used for receiving the polishing result of the polishing machine and issuing a polishing instruction according to the polishing result until the polishing operation of the polishing piece is completed.

In addition, a preferable embodiment further includes: and the alarm module is arranged in the control system and used for receiving the point cloud data, performing 3D modeling, comparing the difference value between the 3D modeling and a preset model, and giving an alarm when the difference value exceeds a polishing piece in a preset range.

In addition, a preferable embodiment further includes:

the electric main shaft is arranged on the polishing machine;

the tool magazine is arranged in the working range of the polishing machine, and a plurality of tools connected with the electric spindle are arranged in the tool magazine;

the sliding table assembly comprises a transfer track, a base arranged on the transfer track, a bearing platform arranged on the base and a tool support arranged on the bearing platform.

In addition, a preferable embodiment further includes:

a protection component arranged on the bearing platform and comprising a bolt and a spring, wherein,

the bolt penetrates through the bearing platform and is fixedly arranged on the base, and the spring is arranged between the bearing platform and the base.

Furthermore, it is preferred to adapt a sensor to each tool.

In addition, the preferable scheme is that the cooling part is provided, and a plurality of cutters of the tool magazine are arranged in the range of the cooling part, wherein the cooling part comprises an air cooling nozzle and water cooling spray;

the dust suction device is arranged on the sliding table assembly;

and the chip removal device is arranged on the sliding table assembly.

By utilizing the intelligent flexible polishing method and the intelligent flexible polishing device, manual polishing is replaced by machine operation, the polishing track is divided into a plurality of areas through intelligent analysis of a control system, different cutters are used for different areas, the consistency of a polished part is ensured, and the polishing work efficiency is improved. And, carry out the supplied materials inspection through scanning module to the piece of polishing before polishing, to the regional mark of out-of-tolerance, simultaneously, the suggestion staff in time handles, has reduced the human cost, avoids among the prior art polishing operation to the damage of human body, improves work efficiency, guarantees the operation safety.

To the accomplishment of the foregoing and related ends, one or more aspects of the invention comprise the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative aspects of the invention. These aspects are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Further, the present invention is intended to include all such aspects and their equivalents.

Drawings

In the drawings:

FIG. 1 is a flow chart of an intelligent flexible sanding method of the present invention;

FIG. 2 is a control schematic of the intelligent flexible grinding apparatus of the present invention;

FIG. 3 is a process flow diagram of the intelligent flexible grinding apparatus of the present invention;

FIG. 4 is a logic diagram for alarm control of the intelligent flexible grinding apparatus of the present invention;

fig. 5 is a schematic view of the slide assembly and tool magazine of the present invention.

Description of reference numerals:

1. a transfer track; 2. a base; 3. a load-bearing platform; 4. a tool support; 5. a tool magazine; 6. a bolt; 7. a spring; 8. a cutter; 9. and a cooling member.

The same reference numbers in all figures indicate similar or corresponding features or functions.

Detailed Description

In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of one or more embodiments. It may be evident, however, that such embodiment(s) may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing one or more embodiments.

Specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

FIG. 1 is a flow chart of an intelligent flexible sanding method of the present invention; FIG. 2 is a control schematic of the intelligent flexible grinding apparatus of the present invention; FIG. 3 is a process flow diagram of the intelligent flexible grinding apparatus of the present invention;

FIG. 4 is a logic diagram for alarm control of the intelligent flexible grinding apparatus of the present invention; fig. 5 is a schematic view of the slide assembly and tool magazine of the present invention.

As shown in fig. 1, the intelligent flexible polishing method provided by the present invention is provided. The intelligent flexible polishing method is applied to an intelligent flexible polishing device. As shown in fig. 2-5, the intelligent flexible grinding device comprises a grinding machine, a scanning module and a control system.

Wherein the grinding machine is used to control the grinding trajectory and grinding operation of the tool 8. The scanning module is used for collecting point cloud data of the surface of the polished part, determining the space offset of the polished part according to the point cloud data, and determining the polishing track of the cutter 8 and the type of the cutter 8 according to the space offset. The control system is used for receiving the polishing result of the polishing machine and issuing a polishing instruction according to the polishing result until the polishing operation of the polishing piece is completed.

Further, this flexible grinding device of intelligence still includes the alarm module, establishes in control system for receive point cloud data and 3D model, with 3D model and preset model contrast difference, when the difference surpassed the piece of polishing of presetting the scope, the alarm module sends out the police dispatch newspaper.

Furthermore, the polishing machine is also provided with an electric main shaft. The tool magazine 5 is arranged in the working range of the grinding machine and is provided with a plurality of tools 8 connected with the electric spindle. In one embodiment, the electric spindle is built in a motor, the spindle is connected with the tool shank in a rivet mode, and the tool 8 is tensioned and loosened through hydraulic or pneumatic driving. When the tool magazine is used, the polishing machine selects the designated tool 8 according to an instruction of the scanning module, the movable mechanical arm is moved into the tool magazine 5 to select the designated tool 8, the tool 8 is connected with the electric spindle according to the method, and after the connection is completed, the mechanical arm is moved to the operation station again to polish a polished part.

Furthermore, the polishing device further comprises a sliding table assembly, wherein the sliding table assembly comprises a transfer track 1, a base 2 arranged on the transfer track 1, a bearing platform 3 arranged on the base 2 and a tool support 4 arranged on the bearing platform 3, and the polishing piece is arranged on the tool support 4. The scanning module is arranged on the grinding machine and comprises a visual guide unit and a force control sensing unit. The control system is electrically connected to the grinding machine and the scanning module. In one embodiment, an operator fixes and sets a grinding piece on a tool support 4 at a feeding and discharging station, conveys the grinding piece to a grinding station through a transfer rail 1, scans the grinding piece through a scanning module arranged on a grinding machine, confirms whether the scanning piece meets a grinding standard or not, calculates spatial offset for the grinding piece meeting the standard, further obtains a grinding track, and performs grinding operation on the grinding piece; and marking the out-of-tolerance area of the grinding piece which does not meet the standard, and timely giving an alarm.

Wherein, the heavy-duty product is all selected for use to the main components and parts among the transfer track 1, can guarantee that every load-bearing platform 3's payload reaches 6 tons, and two total load-bearing platforms 3 all can polish the material loading. Not only can the whole device work efficiently, but also the service life of the sliding table assembly is ensured to meet the requirement. The tool support 4 is a profiling tool support frame arranged on the transfer track 1, a buffer mechanism is arranged at the bottom of the support frame, the transfer track 1 is protected, and the service life of the transfer track 1 is prolonged.

Furthermore, the device also comprises a protection component arranged on the bearing platform 3, wherein the protection component comprises a bolt 6 and a spring 7, the bolt 6 penetrates through the bearing platform 3 and is fixedly arranged on the base 2, the position relation between the bearing platform 3 and the base 2 is ensured, and the bearing platform 3 and the base 2 are firmly connected and do not displace; spring 7 establishes between load-bearing platform 3 and base 2, slows down the vibration frequency of base 2, plays jar-proof purpose, and then protects and transports track 1 to guarantee that the product on load-bearing platform 3 can not take place the skew. Further, the above-mentioned shock absorbing method can be implemented by a structure other than the spring 7, such as an expansion joint, a U-shaped pipe, etc.

Furthermore, each tool 8 is fitted with a sensor. In one embodiment, the sander is configured to automatically change tools 8, the magazine 5 is a disk magazine 5, the magazine 5 is located adjacent to the sander, and the magazine 5 is configured to store sanding tools 8 of different sizes. Tool magazine 5 is connected with control system electricity to be equipped with the sensor of adaptation in the centre gripping department of cutter 8, realize the mutual biography of signal through linking to each other sensor and control system, and then realize the automatic tool changing of machine of polishing. Under the control of an automatic program, the grinding robot drives the electric spindle to select grinding materials with different specifications to grind different parts on the casting blank.

Furthermore, the intelligent flexible polishing device further comprises a cooling part 9, a plurality of cutters 8 of the cutter base 5 are arranged in the range of the cooling part 9, and after the cutters 8 which are polished are placed into the cutter base 5, the cutters 8 are cooled by spraying gas or liquid through the cooling part 9, so that the service life of the cutters 8 is effectively prolonged. Specifically, cooling member 9 includes air-cooled nozzle and water-cooling spraying etc. and when cooling member 9 was the air-cooled nozzle, the position at last inner wall or side inner wall or storehouse mouth of tool magazine 5 was established to the air-cooled nozzle, passes through the nozzle with compressed air and sprays cutter 8 on, realizes cutter 8's rapid cooling, effectively prolongs the life of abrasive material.

Furthermore, the dust suction device is arranged on the sliding table assembly, and the chip removal device is arranged on the sliding table assembly. Specifically, the dust suction device and the chip removal device are arranged on two sides of the transfer track 1, and the dust suction device can be a high-power dust collector and can adsorb dust generated in the grinding process; the chip removal device can be a chip removal machine and is used for collecting the scraps generated by the polishing machine and transmitting the scraps to the collecting vehicle, thereby effectively reducing the ash falling condition of an operation site, meeting the national relevant standards of safety, environmental protection and dust removal, ensuring the personal health of operators and meeting the standard device requirements.

The intelligent flexible grinding device according to the present invention will be described in detail below with reference to another embodiment.

Firstly, a grinding part is arranged on a grinding tool support 4 and is driven by a sliding table assembly to enter a grinding station, then a grinding machine drives a vision guide unit to scan and photograph burrs and peripheral areas of a workpiece, relevant data are collected, and the actual contour position of the surface of the grinding part and parameter information reflecting the shapes of the burrs, such as the positions, the widths, the heights and the sectional areas of the burrs, are obtained.

Then, the preset polishing path is corrected using the obtained actual profile information of the surface of the polishing member. And judging the burr polishing difficulty information reflected by each parameter of the burr according to a certain rule for the external molded surface, and determining whether to further adjust the modified polishing path.

Finally, the abrasive is ground along the revised (or further adjusted) path. The result that the adjustment of the polishing path brought reflects the polishing effect, and the polishing effect can be ensured for the burrs meeting certain standards.

As shown in fig. 1, the intelligent flexible polishing method provided by the invention comprises the following steps:

s110, scanning the outline of the polished part once to obtain point cloud data, analyzing the difference value between the polished part and a preset model according to a preset algorithm by the point cloud data, and if the difference value exceeds a preset range, sending an alarm by a control system;

s120, dividing the point cloud data into a plurality of areas, analyzing the point cloud data of each area, calculating the spatial offset of each area and the area on the preset model, combining the spatial offset with the polishing area and the polishing process, and determining the polishing track of each area;

s130, polishing the polishing piece for the first time by a polishing machine according to the polishing track of each area;

and S140, after finishing polishing of each area, uploading polishing results to the control system by the polishing machine, and issuing polishing instructions of the next area after the control system confirms the polishing results until polishing of polishing tracks of all the areas is finished.

Further, to the polishing piece secondary scanning after accomplishing the first time of polishing, control system confirms the space offset of polishing the piece to the point cloud data analysis of secondary scanning, wherein, when space offset is greater than and predetermines the offset, then control system sends the instruction of polishing and treats the position coordinate of polishing to the polishing machine, the position segmentation of polishing is treated to the polishing machine, simultaneously, secondary scanning can also discern and polish and have or not the burr on the piece, whether accord with the standard after the completion of polishing, carry out the secondary to the position that does not accord with the standard and polish. In one embodiment, the polishing track may be rectangular or circular or rectangular with circular arcs, one polishing algorithm and one polishing tool 8 are adopted for linear polishing, and the other polishing algorithm and the other polishing tool 8 are adopted for circular arc polishing, so that the polishing track is divided into a plurality of different areas, and the polishing is performed in sequence until all polishing is completed, thereby effectively ensuring the polishing quality and the polishing speed, and ensuring the consistency of the polished workpiece after polishing.

Further, in S110, point cloud data are converted into a three-dimensional model, the three-dimensional model is compared with a preset model in a control system to confirm the polished bulge phenomenon, and when the bulge phenomenon occurs, the control system marks a bulge area and gives an alarm, so that manual follow-up rapid processing is facilitated, and the working efficiency is improved. The scanning of the surface of the grinding part can be omitted as scanning of a plurality of key areas, and the working efficiency can be improved more quickly.

Furthermore, the compensation value of the space offset is manually regulated and controlled, and the grinding times of the grinding piece are determined according to the compensation value and the feed amount of the grinding machine. In one embodiment, an operator can control the offset compensation value set on the polishing software on a display of a control system or an operation table on the site, and divide the offset compensation value into multiple offsets according to the feed amount, so that the cutter 8 is prevented from colliding with the cutter, and the service life of the cutter 8 is prolonged. After finishing the burr polishing of each area, the polishing machine feeds back a polishing result to the control system, and the control system sends out a next polishing instruction until all polishing tracks are finished.

Hereinafter, the intelligent flexible polishing method and apparatus according to the present invention will be described in detail by way of more specific examples.

The intelligent flexible polishing device can ensure that a polished product can obtain better surface processing quality in the grinding process. The intelligent flexible grinding device comprises a control system, a scanning module and a grinding machine, wherein an alarm module is further arranged in the control system. Specifically, the intelligent flexible polishing device executes operation according to an intelligent flexible polishing method.

Polishing the product: the counter weight iron of fork truck.

Polishing the field: closed dust removal room.

The grinding principle is as follows: after a polishing piece is placed steadily and is fixed well on polishing robot's furniture, through removing slip table subassembly immigration station of polishing, at this moment, polishing robot takes 3D laser head to scan the characteristic region of polishing piece, the point cloud data of vision guide element to gathering is analyzed, the processing, calculate the 3D skew data of polishing, vision calculation is handled and is accomplished the back, polishing robot revises the orbit of polishing and polishes according to the skew data that the vision guide element provided, also can reserve the function expansion ability of the defect analysis on polishing piece's surface through point cloud data, can effectively measure every product burr size. During the polishing period, the force control sensing function monitors the polishing track of the cutter 8 in real time, and the cutter 8 is prevented from colliding.

Grinding standard:

(1) burrs and seam slipping of a grinding balance block of the grinding robot are carried out, and the quality of the cast after grinding is within-1-0 mm;

(2) positioning accuracy of the visual guidance unit: plus or minus 0.5mm, and the repeated positioning precision in the secondary scanning is plus or minus 0.1mm.

And (3) grinding process:

1. the size error of the same variety and batch of castings is within +5 mm;

2. workpiece loading and unloading: the workpiece is manually lifted to be on-line and off-line by a workshop, and is manually fixed on a support tool;

3. the manual clamping mode is accurate in positioning and convenient and reliable in clamping, and the clamping time is not more than 60 seconds;

4. adjusting the position error of a die assembly seam of the workpiece by the 3D laser head;

5. simultaneously polishing by two robots;

6. cutting a casting head or oversized burrs and flashes;

7. and (4) polishing all burrs and flash of the workpiece (except that the cutter 8 cannot be contacted due to tool interference and the complex structure of the workpiece).

8. Burr shape: the burr is the slice totally, distributes in work piece casting die joint, profile boundary and drill way department etc. and in addition, the cubic residue after the dead head knocks off also needs to polish and gets rid of. Wherein, the work piece needs artifical preliminary treatment before polishing, beats and gets rid of too big burr, and the locating hole and the locating surface are polished to the manual work to guarantee automatic grinding device effect of polishing.

9. The appearance surface of the finished casting is not higher than the bulge phenomenon of the target surface, and the casting polishing quality is within-1-0 mm;

10. all polished positions have to be shape-following, smooth and flat, and can not have acute angles and sharp edges, and the sharp positions which can not be cut by hands can not be touched by hands;

11. the grinding cycle is controlled at 30 minutes, i.e. one workpiece can be removed from the grinding system off-line every 30 minutes.

The production conditions are as follows:

1. the polishing rhythm is controlled to be 30 minutes, namely, one workpiece can be discharged from the offline position of the polishing system every 30 minutes;

2. the appearance surface of the polished casting cannot have a protrusion phenomenon higher than that of a target surface, and the polishing quality of the casting is within-1-0 mm;

3. all the polished positions must be shape-following, smooth and flat. Acute angles and sharp edges are not allowed. The sharp part where the hand can not be cut is touched by the hand;

4. the overall noise is less than 85db;

5. environmental conditions are as follows:

(1) power supply: 380/220V +/-10 percent and 50HZ +/-20 percent;

(3) temperature: 0 to 45 ℃;

(3) relative humidity: the coldest month averages 77%, the hottest month averages 85%.

Grinding the product:

and (4) polishing by adopting a brazing CBN abrasive according to the material quality and the burr condition of the workpiece. CBN is a synthetic superhard abrasive, the hardness is second to diamond, but the heat resistance and chemical stability are far higher than diamond, and the CBN is more suitable for cast iron grinding. On the other hand, the brazing process can ensure the effective available height and chip containing space of the grinding material, and is more suitable for rough grinding compared with the electroplating process.

The abrasive can be designed into various shapes according to the requirements of different grinding positions of a workpiece, can be cut and ground, has the appearance of the abrasive and corresponding processing, and is favorable for optimizing the grinding path of the robot.

Grinding step (in this embodiment, the number of grinding robots is two):

1. firstly, start this flexible grinding device's of intelligence control system, the system carries out the self-checking, hangs the loading frock department of delivering to outside the room of polishing and carries out basic inspection to the weight iron through hoist and mount afterwards.

2. Then, fix the counter weight iron on polishing robot's anchor clamps in material loading frock department, at this moment, material loading department includes two material loading mouths, A end and B end respectively, it has scan module to judge whether material (being equivalent to counter weight iron) is on the fixed position of anchor clamps to press the start button, the judged result is for there being the material, then move polishing robot to the position of polishing by the slip table subassembly, the judged result is for there being no material, then wait for the material, transport to the position of polishing again for there being the material until detecting the result, send to the position of polishing after, the slip table subassembly triggers stop signal. Specifically, both ends of a ground rail (equivalent to the transfer rail 1) in the sliding table assembly can be loaded and unloaded.

3. And when the sliding table assembly stops, the control system starts a starting signal of the polishing robot. The 3D laser heads of the scanning modules on the polishing robot A and the polishing robot B scan the mold closing seam on the counterweight iron, and the internal programs of the scanning modules automatically complete related algorithms and upload data to a PLC master control system (equivalent to a control system).

4. The polishing robot scans a local characteristic region (or all characteristic regions) of the counterweight iron through the 3D laser head to obtain point cloud data of the region.

5. The PLC master control system receives point cloud data of a 3D laser head scanning counterweight iron and analyzes and processes the point cloud data of key parts (grinding possibly interference areas), a standard model in the PLC master control system is compared with the counterweight iron, the difference between the standard model and the counterweight iron is obtained, and if the counterweight iron is out of tolerance seriously, an alarm is given through an alarm module.

6. Analyzing and processing point cloud data of key positions (polished areas possibly interfered), comparing a standard model in the PLC master control system with a counterweight iron, and then confirming the bulge, marking the area of the bulge by using software if the bulge position exists, conveniently performing manual follow-up processing on problem points, alarming through an alarm module, and prompting an operator to perform immediate processing.

7. According to the combination of a casting process, a polishing position and a polishing process preset in the PLC master control system, the balance weight iron is divided into a plurality of areas, point cloud data in the areas are analyzed, processed and local features are extracted respectively, and the spatial offset between the local features of the actual workpiece and the local features of the standard workpiece is calculated.

8. The grinding robot combines the grinding robot with the workpiece coordinate system locally corresponding to the workpiece through updating according to the data of the spatial offset, and the grinding track is adjusted by adopting a sectional type means.

9. The polishing robot selects a cutter 8 according to the instruction of the scanning module, the PLC master control system opens the tool magazine 5 and the air blowing devices in the dustproof room and the tool magazine 5, and the polishing robot performs the first polishing operation according to the adjusted polishing track. During the period, the operator can control the grinding software on the operation table on the site to set the offset compensation value, and the operator can divide the offset compensation value into a plurality of offsets according to the feed amount.

10. And when finishing the polishing of one area, the polishing robot feeds back a polishing result to the control system and the visual guide unit, and the visual guide unit receives the polishing result and issues a next polishing instruction until all polishing tracks are finished.

11. After the counterweight iron is polished for the first time, the counterweight iron needs to be scanned for the second time, the polishing result is guaranteed to meet the standard, if the trajectory of burr residues on the counterweight iron is detected after the second scanning, the visual guide function independently issues a polishing instruction, and the polishing robot performs secondary polishing in a segmented mode. Wherein, the standard of secondary grinding is as follows: the residue is higher than the casting body (balance weight iron or workpiece) by a certain height, and the scanning module sends the coordinates of the part to be secondarily polished to the polishing robot through software.

12. After the secondary scanning or the secondary polishing is finished, the PLC master control system issues an instruction to the polishing robot A and the polishing robot B, so that the polishing robot A and the polishing robot B automatically finish polishing of the mold closing seam and the casting gate. During the period, the grinding robot carries out the self-judgement to relevant compound die seam, and during the period of polishing, the grinding robot is according to the regional different automatic tool changeings of polishing.

13. After the balance weight iron is polished, the balance weight iron is moved out of the polishing station to the feeding port through the transfer rail 1, an operator performs feeding operation, the balance weight iron (workpiece) which is not polished is moved into the polishing station through the transfer rail 1, and single circulation is finished.

For better satisfying the requirement of polishing, according to the characteristic of counter weight iron casting, tested multiple abrasive material, it is different according to the position of polishing at last, designed the abrasive material of polishing of difference, the abrasive material through with following mode integrate: abrasive material-cutter bar-HSK 63A cutter handle-electric spindle. The abrasive material can be replaced manually after being worn, and the other parts are standard parts and can be recycled.

The grinding time of the single workpiece in the grinding step is controlled within 30 minutes.

Alarm control logic: during the operation of the control system, three alarm conditions are included: the device comprises an alarm, an emergency stop button and a stop button.

Wherein the activation of the device alarm includes both a catastrophic failure and a minor failure. When the fault is serious, the device is stopped emergently and displayed by the HMI, and the system is automatically reset and restarted after the fault is cleared. And when the fault is slight, the device is suspended and displayed by the HMI, and when the fault is clear, the system continues production operation.

When an emergency stop button is pressed in case of emergency, the device is emergently stopped and displayed by the HMI, and when the fault is cleared, the system automatically resets and restarts.

Wherein, operating personnel presses the stop button, and this flexible grinding device of intelligence stops in proper order.

The intelligent flexible polishing method, device and device related by the invention need to comprehensively consider various factors in the system design process, wherein the most important factors comprise:

1. high reliability, high availability

Since the system is responsible for critical production-related traffic, it is necessary to ensure uninterrupted service to the customer, which requires that the computer system be operated continuously for 7 × 24 hours, in view of the high reliability of the system, during the device model selection process.

2. Extensibility

In the information field which is developed rapidly nowadays, the application environment, the software and the hardware of the system are updated continuously, so the flexibility and the expandability of the computer system must be considered, and the expansion is premised on that the overall architecture of the system is not changed.

3. Practicality and economy

When the system is designed and the device is selected, the reasonable allocation of resources is fully considered, so that the whole system has the highest performance/price ratio; and a database, middleware, tool software and application software of the current production system are supported, so that a user can add related devices on the basis of protecting the existing investment and flexibly expand the system.

4. Advancement and maturity

With the development of information technology, many new technologies and products are developed, but in order to guarantee the stability and reliability of the system, the new technologies and successful experiences are fully utilized on the premise of giving priority to mature products. The products and technologies recommended in the project are in line with the development trend of the current information technology, include advanced technologies and development space, and are recognized mature products and technologies with advanced technologies and complete functions in various fields.

Wherein, this flexible grinding device of intelligence includes control system, the machine of polishing, slip table subassembly, tool magazine 5 and scanning module. The control system comprises a PLC master control system and an industrial personal computer operation processing system, and the PLC master control system can realize safety detection and scheduling of all devices (in the implementation); the sliding table assembly is a double-station movable sliding table assembly, manual feeding and discharging and polishing of the polishing robot are achieved through the double-station sliding table assembly, the sliding table assembly comprises a transfer track 1, a base 2 arranged on the transfer track 1, a bearing platform 3 arranged on the base 2 and a tool support 4 arranged on the bearing platform 3, and a polishing piece is arranged on the tool support 4; the scanning module is a 3D laser scanning system and comprises a visual guide unit and a force control sensing unit, the visual guide unit has scanning and guiding functions, and the scanning module realizes positioning and deviation compensation of a grinding piece, wherein the scanning is 3D laser scanning and guides the grinding robot to work, a coordinate system of the visual guide is the same as that of the grinding robot, and the grinding robot is guided to work according to a scanning comparison result; the grinding robot is an ABB IRB 6700-200/2.60 robot, and an autonomously developed grinding system is arranged on the grinding robot.

Be equipped with electric spindle on polishing the robot, electric spindle has intelligent perception function can with 8 automatic connections of cutter in the tool magazine 5, simultaneously, installs the 3D laser head on every polishing the robot's anchor clamps. The tool magazine 5 is arranged in the working range of the grinding robot, a plurality of tools 8 connected with the electric spindle are arranged in the tool magazine, the number of the tools 8 is at least three, and the tools 8 can be matched with various grinding modes of grinding products. The control system is electrically connected with the polishing robot and the scanning module, receives the scanning data of the scanning module and issues a next step instruction according to the polishing track.

The software in the intelligent flexible polishing method and the intelligent flexible polishing device mainly comprises three functions:

1. a counterweight iron surface defect positioning module:

1. and (4) when the workpiece is in place, the vision guide unit starts to prepare for 3D scanning after receiving an in-place signal of the PLC master control system.

2. The polishing robot runs to the start position to start scanning for the scanner, the polishing robot drives the scanner to start scanning according to a pre-planned path in a 0.1mm pulse width signal mode, and the vision system starts calculating after the whole scanning track is run.

3. And comparing the standard model with the standard model to obtain the difference between the standard model and the standard model, and alarming if the product is seriously out of tolerance. (an out-of-tolerance may interfere with the grinding path, possibly causing damage to the robot or end tool)

4. Meanwhile, bulge confirmation is carried out, if bulge is confirmed, bulge area marking is carried out through software, and display is carried out at the front end, so that manual subsequent processing is facilitated;

2. a counterweight iron 3D reconstruction algorithm module:

and (3) scanning the workpiece to obtain point cloud data, modeling, comparing with a standard model to obtain the position offset of the casting, and correcting the polishing track by the robot according to the offset.

1. And analyzing and processing the acquired point cloud data by the visual guide unit according to the data obtained by the scanner, and calculating the 3D position of the polishing part.

2. According to the casting process, the polishing position and the polishing process, a workpiece is divided into a plurality of local areas, the laser head scans the local characteristics of the workpiece, the spatial offset between the local characteristics of the actual workpiece and the local characteristics of the standard workpiece is calculated, and the polishing track is adjusted in a sectional mode by the robot through a method of updating the workpiece coordinate system corresponding to the local part of the workpiece according to the offset data.

3. The grinding robot analyzes the control command to select a specified tool bit and grinds the burrs; if a plurality of tool bits are needed for polishing the burrs, the robot system automatically switches and polishes the tool bits according to instructions and the preset rule of tool bit selection.

4. When a burr grinding process is finished, the robot system feeds back a grinding result to the control system and the visual guide unit, and the visual guide unit sends a next grinding instruction; until all grinding tracks are finished.

5. After all burr polishes are completed, the vision system completes the polishing.

6. And finishing the automatic grinding of the workpiece.

7. After polishing is completed, after the PLC master control system receives a completion signal, the sliding table assembly moves to a discharging position to wait for a next workpiece in-place signal.

8. And each scanning, modeling and path planning time is controlled within 5 minutes.

3. Counterweight iron control module:

1. the position of the burr of the same workpiece is different, different tool bits are needed to be adopted for polishing, the software presets polishing tool bits corresponding to polishing areas according to preset rules, data interaction is carried out on the polishing tool bits and the polishing robot, an instruction of the polishing robot for executing a corresponding program is sent, and meanwhile, a polishing path deviation calculation result is sent to the polishing robot. The grinding robot grinds according to the deviated track, and the path comprises a grinding feed point, a grinding withdrawal point and a position coordinate and complete motion track information, wherein the grinding feed point and the grinding withdrawal point are taken as initial points, and the position coordinate and the complete motion track information are reached by the grinding robot;

2. the grinding robot analyzes the control command to select a specified tool bit and grinds the burrs; if a plurality of tool bits are needed for polishing the burrs, the polishing robot combines preset tool bit selection according to instructions to perform automatic tool bit switching polishing; when a burr grinding process is finished, the grinding robot feeds back a grinding result to the control system and the visual guide unit, and the visual guide unit issues a next grinding instruction until all burr grinding tracks are finished.

The intelligent flexible polishing method and the intelligent flexible polishing device have the following advantages that:

1. according to the intelligent flexible polishing method and device, the polishing operation of the polishing machine is guided by adopting 3D laser line scanning, the polishing path is corrected through the deviation of the coordinate system, and the polishing times can be determined through the function of compensating the deviation through software, so that the polishing quality of a polished part is ensured.

2. The intelligent flexible grinding method and the intelligent flexible grinding device can directly carry out grinding operation on the cast iron casting, the grinding path is planned in a segmented mode through the scanning module, corresponding grinding materials are selected in different paths, the integral grinding quality is guaranteed, and in the grinding process, an electric spindle on a grinding machine can automatically change tools, so that the intelligent flexible grinding method and the intelligent flexible grinding device are more intelligent.

The intelligent flexible polishing method and the intelligent flexible polishing device can be changed according to the weight, the size, the polishing precision and the process flow of the tool and the workpiece above the actual machine. The brand of the grinding robot is not limited to ABB, and other robots may be used, such as KUKA, FANUC, and the like.

The intelligent flexible sanding method and apparatus according to the present invention are described above by way of example with reference to the accompanying drawings. However, it will be appreciated by those skilled in the art that various modifications may be made to the intelligent flexible sanding method and apparatus of the present invention without departing from the scope of the present invention. Therefore, the scope of the present invention should be determined by the contents of the appended claims.

Claims (10)

1. An intelligent flexible polishing method is characterized by comprising the following steps:

s110, scanning the outline of the polished part once to obtain point cloud data, analyzing the difference value between the polished part and a preset model according to a preset algorithm by the point cloud data, and if the difference value exceeds a preset range, sending an alarm by a control system;

s120, dividing the point cloud data into a plurality of areas, analyzing the point cloud data of each area, calculating the spatial offset of each area and the area on the preset model, combining the spatial offset with the polishing area and the polishing process, and determining the polishing track of each area;

s130, polishing the polishing piece for the first time by a polishing machine according to the polishing track of each area;

and S140, after finishing polishing of each area, uploading a polishing result to the control system by the polishing machine, and issuing a polishing instruction of the next area after the control system confirms the polishing result until polishing of polishing tracks of all the areas is finished.

2. The intelligent flexible sanding method of claim 1 further comprising:

and secondarily scanning the polished part after the primary polishing, analyzing point cloud data of the secondary scanning by the control system to determine the spatial offset of the polished part, wherein when the spatial offset is greater than the preset offset, the control system sends a polishing instruction and coordinates of the position to be polished to the polishing machine, and the polishing machine polishes the position to be polished in a segmented manner.

3. The intelligent flexible sanding method of claim 1 further comprising:

in S110, the point cloud data is converted into a three-dimensional model, the three-dimensional model is compared with a preset model in a control system to confirm the polished bulge phenomenon, and when the bulge phenomenon occurs, the control system marks a bulge area and gives an alarm.

4. The intelligent flexible sanding method of claim 1 further comprising:

and regulating and controlling the compensation value of the space offset, and determining the grinding times of the grinding piece according to the compensation value and the feed amount of the grinding machine.

5. An intelligent flexible grinding apparatus for performing the intelligent flexible grinding method according to any one of claims 1 to 4, comprising:

the grinding machine is used for controlling the grinding track and the grinding operation of the cutter;

the scanning module is used for acquiring point cloud data of the surface of the polished workpiece, determining the spatial offset of the polished workpiece according to the point cloud data, and determining the polishing track of the cutter and the type of the cutter according to the spatial offset;

and the control system is used for receiving the polishing result of the polishing machine and issuing a polishing instruction according to the polishing result until the polishing operation of the polishing piece is completed.

6. The intelligent flexible sanding device of claim 5 further comprising:

and the alarm module is arranged in the control system and used for receiving the point cloud data, performing 3D modeling, comparing the difference value between the 3D modeling and a preset model, and giving an alarm when the difference value exceeds a polishing piece in a preset range.

7. The intelligent flexible grinding device of claim 5, further comprising:

the electric main shaft is arranged on the polishing machine;

the tool magazine is arranged in the working range of the polishing machine, and a plurality of tools connected with the electric spindle are arranged in the tool magazine;

the sliding table assembly comprises a transfer track, a base arranged on the transfer track, a bearing platform arranged on the base and a tool support arranged on the bearing platform.

8. The intelligent flexible sanding device of claim 7 further comprising:

a protection component arranged on the bearing platform and comprising a bolt and a spring, wherein,

the bolt penetrates through the bearing platform and is fixedly arranged on the base, and the spring is arranged between the bearing platform and the base.

9. The intelligent flexible grinding device of claim 7,

one sensor is adapted to each tool.

10. The intelligent flexible grinding device of claim 7, further comprising:

the cooling part is arranged in the range of the cooling part, and comprises an air cooling nozzle and water cooling spray;

the dust suction device is arranged on the sliding table assembly;

and the chip removal device is arranged on the sliding table assembly.

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